CEMENT TEST EQUIPMENT, INC.TULSA, OKLAHOMA, USA
Contents
1. 8 7 6 THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF CEMENT TEST EQUIPMENT INC ANY REPRODUCTION IN PART OR WHOLE WITHOUT THE WRITTEN PERMISSION OF CEMENT TEST EQUIPMENT INC IS PROHIBITED Le IE NSS zu 2 ZOTZA p KKV ENE MAP 4 RPR SECTION A A SCALE 1 1 8 7 6 NEXT ASSY USED ON APPLICATION REVISIONS REV DESCRIPTION DATE APPROVED PART NO DESCRIPTION 1 1 2 0052 Mounting Frame 2 1 2 0053 Spring Adjuster 3 1 2 0054 Spring Adjuster Clamp Bearing insulator oO 2 0058 Stop Arm Spring Collar 6 4 Spring Sleeve Contact Pin Spring Shaft Bearing Retainer 11 2 0063 Mounting Frame Stop 12 C 0086 Bearing Potentiometer Slider 14 1 Spring 15 1 Ground Pin Spring 16 1 Resistor 17 1 2 0066 Ground Wire not shown UNLESS OTHERWISE SPECIFIED CAD GENERATED DRAWING DIMENSIONS ARE IN INCHES DO NOT MANUALLY UPDATE CEMENT TEST EQUIPMENT INC TOLERANCES ARE FRACTIONS DECIMALS ANGLES 1 32 XX 011 PRAWN CCD 3 27 97 APPROVALS DATE XXX 005 se HE 3 27 97 POTENTIOMETER MECHANISM ASS Y RESP ENG CCD 3 27 97 FINISH MFG ENG CCD 3 27 97 aa DWG NO 2 0050 QUAL ENG IE CCD 3 27 97 seat 1 CAD FILE SHEET 1 OF 1 2 3 8 7 6 5 4 3 2 1 THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF REVISIONS CEMENT TEST2. files is C CTE Tests This folder also stores the actual test parameters so any test deleted cannot be run again without reprogramming TEST SETUP EDIT INSTRUMENT This button should only be used when instructed to by CTE 11 A TOUR OF THE FRONT PANEL CONTROLS TEST SETUP From this menu the user can enter or reset a temperature ramp and soak schedule The user can also configure the hesitation squeeze and gel strength parameters on equipped instruments TOUCH TO PROGRAM TEMPERATURE SIONO MEST Cu BOGEN Retrieve Test Setup MT PTA O TA A SIMILAR BOX APPEARS ON PRESSURE CONTROLLED UNITS FOR PRESSURE RAMP CHANGE ANY ADDITIONAL TEST PARAMETERS OR ADD INFORMATION TEMPERATURE CONTROL PRESSURE WHEN AVAILABLE The Program Temperature screen is shown below Set Point gt Ramp Time min SOAK 12 A TOUR OF THE FRONT PANEL CONTROLS Enter desired set point values by touching the SET POINT parameter box and entering the values on the keypad Time to set point is selected by touching the TIME parameter box and entering a time in minutes on the touch pad The final segment should always be a SOAK segment where the temperature equals the final test temperature and the time equals SOAK This guarantees the instrument will maintain final temperature for the remainder of a test After a profile has been entered press the SAVE button At this point a graph of the de
3. C BLACK INSTRUMENT MEASUREMENT COMPUTING C 1181 TRANSDUCER D BROWN BACK PANED 0 GROUNDS 30 33 39 49 pare USB H IL C 0022 Transducer for 22K amp 40K units C 0629 C 0096 Transducer for 20K units SE 05 26 09 WIRING SCHEMATIC RED D RESEVOIR T C CEMENT TEST EQUIPMENT ING WHITE 05 26 09 CONSISTOMETER v5 BLUE A c 0167 BROWN A CONNECTOR 05 26 09 FROM CON206 05 26 09 f Fr C 0377 MOTOR a p _03 0300 ELE los 26 09 kr SPEED POT v 4 2 C 0466 PRESSURE GAUGE C 0049 COLLAR 6 C 0050 GLAND C0018 TEE C 0050 GLAND C 0049 COLLAR C 0022 PRESSURE TRANSDUCER C 0146 SAFETY HEAD C 0285 CONNECTOR C 0243 RUPTURE DISC 25000 PSI C 0840 ELBOW 11 0020 PRESSURE VESSEL ASS Y C 0018 TEE C 0191 ADAPTER 2 0071 FILTER ASSEMBLY C 0191 ADAPTER C 0002 1 VALVE PRESSURE RELEASE A C 0049 COLIAR C 0179 CONNECTOR C 0040 ADAPTER C 0054 ELBOW C 0181 ELBOW C 0760 VALVE COOLING COIL ASSEMBLY 0 0840 ELBOW C 0049
4. COLLAR 0181 ELBOW SOLENOID VALVE C 0050 GLAND C 0285 mr TUBE C 0696 ELBOW 0181 ELBOW r I 0179 CONN 0 0575 PUMP C 0 I 3 0049 CAPILLARY C 0389 SOLENOID C 0051 1 TEE C 1091 ADAPTER C 0027 ADAPTER C 0284 ELBOW C 0051 1 TEE C 0024 SOLENOID VALVE AIR TO CYL 3 0046 DIP TUBE C 0051 1 TEE pe r C 0689 CHECK VALVE C 0021 REGULATOR C 0180 ELBOW I Ns 1 TEE C 0364 x m o O 6 m GAUGE I C 0689 CHECK VALVE REGULATOR 0 0180 ELBOW 0181 ELBOW 2 6 1304 SOLENOID VALVE H EA 3 SIGHTJGLASS C 0146 SAFETY HEAD C 0285 CONNECTOR C 0243 RUPTURE DISC 25000 PSI C 0018 TEE TRANS 0840 ELBOW 11 0020 PRESSURE VESSEL ASS Y COOLING COIL C 0191 ADAPJER ASSEMBLY 2 0071 C 0840 ELBOW C 0181 CYLINDER COOLING C 0051 1 C 0689 CHECK A a C 0055 CONN C 0024 SOLENOID VALVE FILL CYLINDER C 0197 FILTER 3 0013 FILTER HOUSING C 0890 EtBow I I I al I 4 0 0055 CONN 3 0042 OIL RESERVOIR C 0289 O RING C 0545
5. HOUSING se mares 37 INSTRUMENT 7 10 HEATER REPLACEMENT ann 38 TEST SETUP een abcd ete nennen 12 TROUBLESHOOTING DA EINE WENN 40 STARTTEST arrene 15 STOPPING A TEST 16 SOFTWARE UPGRADES 16 USING THE USB MEMORY STICK AND PRINTER hive 17 A TOUR OF THE FRONT PANEL CONTROL 18 THE HYDRAULIC PRESSURE CONTROLS 18 THE PNEUMATIC CONTROIS 19 THE COOLING WATER CONTROLS 20 OTHER ELECTRICAL AND ELECTRONIC CONTROLS Hestnes 21 OPERATION AND CALIBRATION 23 A BRIEF EXAMPLE OF RUNNING THICKENING TIME TEST 23 A BRIEF EXAMPLE OF STOPPING A THICKENING TIME TEST 24 CALIBRATION anera rene AE 25 PRESSURE CALIBRATION PROCEDURE 26 CONSISTENCY CALIBRATION PROCEDURE MAINTENANCE SERVICING AND TROUBLESHOOTING 29 5 Important 2 Potential Danger or ICON KEY Information Safety Hazard Operational Warning INTRODUCTION Chapter Introduction This chapter contains general information about the consistometer and is uses as nell as detailed speafications for the instrument What is a consistometer used for Cements are a critical element in the drilling completion workover and abandonment of wells For each application cement slurry is designed with specific properties and is given additives that provide
6. OPEN DRAIN AR2CYL RED COOL SWITCH cs RES COOL C 0489 SWITCH 004896 e o 9 YELLOW POWER NE SWITCH Er GAGE YELLOW 6 0075 I 18 C 0585 FUSE BLOCK DP 2 AUTO OFF ON YELLOW oe SSR PUMP SWITCH C 0132 RED C 0478 x YELLOW 18 4 SSR BLOCK C 1260 Yellow 18 Fine 5 tod HEATER SW C 0075 1 56 Red 18 RED YELLOW YELLOW 12 WHT BLK WHT RED JO YELLOW 1p 03 0023 HEATER All Heater AC wiring is White Red 12 gauge White Blue White Orange All other AC wiring is 0481 White Purple 18 gauge OWER SUPPLY White Black CONTROL BOX MOTOR SW Jumper 12v for C 0096 C 0075 1 For C 0096 24V hor c 0022 v5 Line So N 04 0071 C E G D A GREEN CYLINDER go D7 ps p D3 DO AE B WHITE Zaire a 43 44147 las 48 c 0022
7. Resistor 1 Remove 2 0064 Shaft Bearing Retainer and 2 0077 Potentiometer Slider Remove old resistor from 2 0052 Mounting Frame being careful not to damage slot Position new resistor over the slot in the mounting frame with the straight side down The 2 0051 Connecting Strip must be installed under the resistor in the groove in the mounting frame The length of resistor extending past the connecting strip should be approximately even on both ends Seat the resistor securely in the slot in the mounting frame Use care to avoid damage to the resistor The top surface of resistor must be level with the top of the mounting frame Use a smooth round rod such as the round shank of a screwdriver to rub top surface of resistor burnishing resistance wire lightly so potentiometer slider will slide smoothly with minimal noise 34 The spring should wind tighter when the slider is moved in the counter clockwise direction Rotate potentiometer slider by hand Assure that slider makes contact with the resistor during its entire range of motion If necessary adjust slider by bending it up or down Replace shaft bearing retainer and check the potentiometer mechanism with a calibrating device Potentiometer Mechanism Spring Replacement Refer to drawing 2 0050 when replacing the 2 0060 Spring 1 Remove 2 0064 Shaft Bearing Retainer and 2 0077 Potentiometer Slider Remove old spring Install new
8. TEMPERATURE 2 Disconnect thermocouple from inside instrument The plug is located behind the heater Connect the Temperature calibrator to this plug 3 Enter a value of 125C or 275F in the calibrator 4 Verify that the RAW VALUE on the touchscreen is changing as you enter a new number into the calibrator This time enter 25C or 60F into the calibrator 5 Enter the same temperature value into the LOW VALUE box in CementLab 6 Select SAVE LOW VALUE 7 On the calibrator input 220C or 400F 8 Enter the same number into the HIGH VALUE box in CementLab 25 9 Select SAVE HIGH VALUE 10 On the calibrator enter 100C or 200F 11 Verify the calibration is reading the same value on the touchscreen 12 Select SAVE or DONE and Exit Calibration screen Pressure Calibration Procedure Pressure may be calibrated using a Digital Pressure Calibrator Simply remove pressure vessel and attach calibrator to the thermocouple port on top of the cylinder If equipped with software pressure display start the CALIBRATE PRESSURE routine as was done for Temperature Ensure no pressure is on the pressure vessel and enter zero as the LOW VALUE SAVE LOW VALUE FILL the cylinder with oil and then verify pressure gauge readings at different pressures If optional software pressure display has been purchased pressure unit to maximum typical operating pressure and input the digital calibrator gauge reading into the HIGH VALUE of the software
9. as punch to loosen the heater ferrules 11 With the 3 0025 Heater Gaskets removed from the heater insure that the heater is bent so that it drops through the heater holes with minimal effort and that the heater coils lay flat against the pressure vessel bore Forcing the heater into the holes usually deforms the heater and makes the slurry rub the heater An installed heater is almost impossible to bend Remove both C 0250 Heater Nuts Tap on heater ferrules until loosened then pull heater out through bore of pressure vessel Make certain that the 3 0025 Heater Gaskets came out with the heater If the gaskets did not come out a 7 16 inch bolt or tod inserted through the bottom of the heater holes will normally snag the gasket and push it out In lieu of this a screwdtiver may be used to push the gasket out Be careful not to damage the sealing surface inside the heater holes Clean the bottom of the pressure vessel and the heater holes before installing new heater Assembly is the reverse of assembly 39 Troubleshooting The following section consists of a table listing possible remedies for the most common consistometer problems Remedy System builds pressure but will not hold pressure System builds pressure and oil runs out between pressure vessel and top plug Pump strokes but little or no pressure is obtained Pump builds and Leak PRESSURE RELEASE and AIR TO CYLINDER valves are no
10. c 0217 FUSE 30IX2 YELLOW ROSA Yellow 18 Line 5 Load HEATER SW C 0075 1 oe Red 18 WHT BLK WHT RED JO YELLOW 1p 03 0023 HEATER All Heater AC wiring is White Red 12 gauge White Blue White Orange All other AC wiring is 0481 White Purple 18 gauge OWER SUPPLY White Black CALIBRATOR PLUG 1 BLUE CONTROL BOX 2 BLACK 3 YELLOW MOTOR SW Jumper 12V for C 0096 C 0075 1 For C 0096 24V hor c 0022 v5 Line o N 04 0071 C A GREEN Hp CYLINDER D7 ps p D3 DO AE B WHITE mim 4 43 44147 las 48 c 0022 C BLACK INSTRUMENT MEASUREMENT COMPUTING C 1181 TRANSDUCER D BROWN PAN 0 GROUNDS 30 33 36 39 29 2 y H IL C 0629 C 0022 Transducer for 22K amp 40K units WWE 05 26 09 WIRING SCHEMATIC 016 052509 DUAL CONSISTOMETER Coler LEFT SIDE CENTER z 052609 v5 FROM CON206 BROWN A CONNECTOR ET Revised 12 10 10 JPB o 5 2609 al 03 0300 1
11. calibration screen Be sure you are in the correct units and SAVE HIGHVALUE Next release some pressure and verify the CALIBRATED VALUE is correct SAVE and depressurize drain instrument Consistency Calibration Procedure The consistency should be calibrated by using the consistency calibrator assembly 26 The potentiometer mechanism and the digital meter which indicates consistency should be calibrated by using the potentiometer mechanism calibrator This device applies a known torque to the potentiometer mechanism spring allowing the readout to be observed on the CALIBRATE CONSISTENCY screen In TEST SETUP of software program Calibration of the potentiometer mechanism is described in the example below 1 Set the calibrator near the front edge of the consistometer 2 Install the potentiometer mechanism to be calibrated on the holder Insert the wedge into the open slot nearest the potentiometer ground spring 3 Wind the cord around the potentiometer mechanism frame and over the pulley Place the hanger weight hook in the loop on the end of the cord 4 Install the alligator clips to the potentiometer mechanism springs matching the wire colors to the contact pin wire colors 5 Insert the calibrator plug into the CALIBRATOR socket on the front panel of the instrument 6 From the software IDLE screen select INSTRUMENT SETUP and then select CALIBRATE CONSISTENCY 7 The weight of the hook on the string is 50g T
12. high data point has been established press the SAVE HIGH VALUE button The user can now vary the calibration signal and see how the calibrated signal compares with that of the calibration device in the VERIFY NEW CALIBRATION box If the signals compare favorably press the Accept button to save the calibration The calibration values will be stored in a configuration file and take effect upon exiting the Instrument Setup menu SAMPLE RATE This menu allows the user to select a sampling rate for the Data Acquisition program Rate is given in number of seconds between samples To save data space and achieve acceptable test resolution a sample rate of 30 or 60 seconds is recommended UNITS These menus allow the user to select English or SI units for the Data Acquisition program Additional units may be available as an option ARCHIVE DATA This button allows the user to copy all the test files stored in the consistometer to an archive computer for permanent storage The tests may be saved to the USB memory stick or to a local network folder Note that the program will ask for the storage location and the user may browse to any available drive or folder Once the files are copied from the consistometer to the memory stick the files remain on the consistometer and will still be accessible from the instrument To permanently delete these files the user must go to their stored location and delete them manually The default location for CTE test
13. switches may be left in the ON position Leaving the HEATER switch ON will not heat the instrument unless a test is running If equipped with an external timer a TIMER switch will enable the elapsed timer The part number for the POWER HEATER and MOTOR switches is C 0075 and the part number for the TIMER switch is C 0076 and the timer itself is C 0200 An optional MOTOR SPEED tachometer displays the rotational speed of the slurry cup when the motor is running The SPEED CONTROL potentiometer is used to vary the speed between approximately 25 and 250 rpm The part number for the tachometer is C 0388 and the part number for the potentiometer is C 0397 The touch screen is used to control temperature and pressure or other parameters when available The screen will also display a plot of consistency and temperature pressure etc as a function of elapsed time More in depth explanation of the touch screen capabilities may be found in Chapter 2 A part number 3 0036 thermocouple is plugged into the THERMOCOUPLE connector so the centerline temperature of the 21 A TOUR OF THE FRONT PANEL CONTROLS slurry cup may be monitored The CALIBRATOR socket accepts any standard consistometer calibrator The part number for the THERMOCOUPLE connector is C 0167 and the CALIBRATOR connector is C 0222 The pump switch may be one of two varieties depending on whether the automatic pressure control option is installed If automatic pressure control is
14. ve thrown one in anyway just in case The CTE pressurized consistometers are equipped with a state of the art temperature controller and data acquisition system that provides unparalleled ease of use for the operator The parameters of interest may be displayed in either English or SI units Temperature control and data acquisition is programmed through the use of a touch screen monitor separate PC and keyboard mouse are not required but may be connected through a network cable A plot showing temperature and consistency pressure is optional may be plotted on any compatible ink jet printer The plots may also be transferred automatically to a network or USB drive for use on a separate personal computer PC A photograph of the CTE Inc dual consistometer is shown below Instrument Specifications The specifications below apply to all CTE Inc full size pressurized consistometers ELECTRICAL Input Voltage 230 VAC 10 Input Power 5500W single 11000 W dual Current 24 A single 48 A dual Input Frequency 50 60 Hz MECHANICAL Height 70 in 175 cm Width single 33 in 83 cm dual 51 in 129 cm Depth 29 in 72 cm Weight single 1100 Ib 500 kg dual 2050 Ib 930 kg ENVIRONMENTAL Operating Temperature 32 to 105 F 0 40 C Operating Humidity 0 95 noncondensing HEATER Heater Power 5 000 W Heater Type Internal tubular with MgO insulation Heater Control Solid state relay D
15. C 0281 BULKHEAD FASTENER INLET AIR INLET C 0531 0 0024 SOLENOID Ir CYLINDER COOLING r C 0181 ELBOW ae CONN 5 1 4 SST 1 4 COPPER 1 4 PLASTIC BLACK ol 5 16 PLASTIC BLUE 11 24 97 CEMENT TEST EQUIPMENT INC 11 26 97 11 24 97 11 24 97 PIPING SCHEMATIC CONSISTOMETER WITH PRESSURE CONTROL j 11 0006 Der ne ES 11 24 97
16. ELE _ REDS D RESEVOIR T C C 0096 Transducer for 20K units 0 CEMENT TEST EQUIPMENT INC WHITE 05 26 09 poa SPEED POT Ha 00024 re 4 C 0389 3 4 4 30 VOLTS 50 AMPS gt gt POWER IN COOL AIR TO CYL PRESS PUMP OIL FILL FELIDBAN sog FROM LEFT SIDE 2 WAY Y 2 WAY 2 WAY CYLINDE CONTROL SOLENOID SOLENOID J J SWITCH C 0478 E 5 5 D e OLU OFF NO SOLENOID ACTIVE o DRAIN AIR2CYL RED COOL SWITCH C 048 9 YELLOW SWITCH TERMINAL BLOCK C 0472 YELLOW JUMPERS 18 GAGE YELLOW e Q BE POWER RED YELLOW I2 D UJ C 0585 FUSE BLOCK 2 AUTO OFF ON FUSE 30IX2 ee YELLOW RO RED 2 PUMP SWITCH SSR BLOCK A F C 1260 J 9 YELLOW 18 O 2 Yellow 8 Line y Load HEATER SW C 0075 1 S Red 18 28 on Ww N WHT BLK WHT RED JO YELLOW 1p 03 0023 HEATER All H
17. EQUIPMENT INC ANY REPRODUCTION IN PART OR WHOLE WITHOUT DESCRIPTION DATE T APPROVED THE WRITTEN PERMISSION OF CEMENT TEST EQUIPMENT IS PROHIBITED ITEM NO QTY PART NO DESCRIPTION 2 0052 TEFLON BASE 2 0053 SPRING RETAINER 2 0054 SPRING RETAINER CLAMP C 0085 BEARING 2 0055 INSULATOR 2 0058 STOP ARM 2 0057 WIPER BASE 2 0056 SHAFT SO JO ISIS Q OIN 2 0059 2 GROUND SPRING 2 0061 RESISTOR 2 0064 BEARING HOUSING 2 0063 HANGER WIRE C 0086 UPPER BEARING 2 0077 WIPER 1 2 1 2 2 0059 1 CONTACT SPRING 1 1 1 2 0060 SPRING 17 1 2 GROUND WIRE UNLESS OTHERWISE SPECIFIED CAD GENERATED DRAWING DIMENSIONS ARE IN INCHES DO NOT MANUALLY UPDATE CEMENT TEST EQUIPMENT INC TOLERANCES ARE 5 i FRACTIONS DECIMALS ANGLES TE DRAWN 1 32 XX 01 l CCD XXX 005 CHECKED POTENTIOMETER MECHANISM wama a CCD EXPLODED VIEW FINISH CCD NEXT ASSY USED ON PEA DWG NO 2 0050 EXP REV APPLICATION DO NOT SCALE DRAWING SERIE SFR SHEED T OF I 8 7 6 5 4 3 2 1 THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF REVISIONS CEMENT TEST EQUIPMENT ANY REPRODUCTION IN PART OR WHOLE WITHOUT REV DESCRIPTION DATE APPROVED THE WRITTEN PERMISSION OF CEMENT TEST EQUIPMENT IS PROHIBITED TG 24 amp gt E DO SS i A nn N IE s gt k
18. ERTY OF CEMENT TEST EQUIPMENT INC ANY REPRODUCTION IN PART OR WHOLE WITHOUT THE WRITTEN PERMISSION OF CEMENT TEST EQUIPMENT INC IS PROHIBITED 13 a 0 UN N 8 T N N AN Z N N N AS NG N N N GS G gt NN Geen LT bs saa a ir I ZZZ A 1 4 K S S S S S S S S S S S S S S S S S gt LI lt TE FE FF A N 0 i y 6 N N ER N N A ALL p amp gt ITEM NO QTY PART NO DESCRIPTION va un 0 112 0031 PADDLE 2 1 2 0033 PLUG B 8 3 130033 GASKET 5 1 2 0034 SLEEVE u 6 1 2 0036 COLLAR B SECTION A A 7 1 2 0041 DIAPHRAGM SCALE 3 2 8 1 2 0043 DIAPHRAGM HUB 9 112 0044 RING 10 2 C 0006 O RING 11 1 2 0042 HUB CAP 12 112 0037 DIAPHRAGM SUPPORT 13 112 0039 LOCK RING 14 1 2 0040 DRIVE SHAFT DISC 15 112 0038 DRIVE BAR 16 112 0032 PADDLE SHAFT 17 1 C 0007 ROLL PIN 18 1 0 0008 SHEAR PIN 19 112 0045 A UNLESS OTHERWISE SPECIFIED CAD GENERATED DRAWING DIMENSIONS ARE IN INCHES DO NOT MANUALLY UPDATE CEMENT TEST EQUIPMENT INC TOLERANCES ARE nn 1 32 oe m 1 gt CCD 3 2 98 BA SEE exo ccp 3 298 SLURRY CUP ASSEMBLY om CCD 3 2 98 NEXT ASSY USED ON MEGJENG CCD 3 2 98 DWG NO 2 0030 REV ARPLIGANION DO NOT SCALE DRAWING ECCD 3 2 98 SCALE 3 2 CAD FILE SHEET I OF 1 8 7 6 5 4 3 2 6 D 2 REVISIONS DESCRIPTION DATE APPROVED
19. OTOR INPUTS TOH T C 3 WHI TOL T C 4 RED VO TRANSDUCER VI CONSISTENCY V2 MOTORSPEED WHT RED WHT BLK BROWN BLACK RED BLACK ORANGE BLACK YELLOW BLACK GREEN BLACK BLUE BLACK PURPLE URPLE O o OY OY 01 Q Q N NS Fo 600 Hs 00 Hs CO Hs CO ds CO Hs Hs ds so A O N G Ud OO 0110 OAO ON 0 00 oooooooc oooooo I H gt PIN OUTS C 0763 1 WHI TE RED 2 WHI TE BLUE Usd I DU O I INPUTS w oO BLACK 3 WHITE ORANGE 4 WHITE VIOLET 5 WHITE BLACK PIN OUTS C 1190 1 WHITE 2 RED 3 GREEN 4 BLACK To To Vo Vo V1 V1 T2 T2 H L 4 WHITE CYLINDER T C J TYPE 3 RED 38 GREEN PRESSURE 37 WHITE 35 YELLOW CONSISTENCY 34 BLACK WHIT RED E RESEVOIR T C J TYPE GEMENT TEST EQUIPMENT ING REVISION DESCRIPTION 05 26 09 05 26 09 05 26 09 05 26 09 WIRING SCHEMATIC CONSISTOMETER v5 05 26 09 03 0300 Ev5 i C 0024 INLET POWER c 0024 6 4 5 c 1304 2 3 4 230 VOLTS 30 AMPS COOL AIR TO CYL 3 way JAR RESNOIR PUMP 50 60 HZ 2 WAY SUPPLY 2 WAY COOL 2 WAY CYLINDER 1 POOL EXHAUST 4 SOLENOID FILL DRAIN NC SWITCH C 0478 e OLFILL GREEN 10 OFF EXHAUST
20. RIVE UNIT Drive Motor 1 8 Hp 93 W 180 VDC Drive Speed 25 250 rpm variable UTILITIES WATER AND AIR Compressed Air maximum 150 psig 10 2 bar minimum 80 psig 5 4 bar Cooling Water Pressure 100 psig 6 8 bar maximum Utility Inlets 1 4 inch female NPT It is a good idea to leave room behind the instrument so that qualified personnel may have service access If this is not possible try to make the unit easy to disconnect and move for service Installation Upon uncrating the instrument verify that the instrument and any spare parts on the packing have been received and are undamaged Notify CTE if anything is missing or damaged The instrument s center of gravity is located near the front of the instrument due to the weight of the pressure vessels Be very careful when rolling or transporting the instrument that it does not tip over toward the front Once the instrument has been moved to its desired location air water and electrical connections can be made The air inlet water inlet and water drain connections are each 14 inch female NPT connections and are located on the lower right rear of the instrument A number of 14 inch male NPT to 8mm tube fittings are included for international locations The air and water inlet connections may be made with either metal or plastic tubing It is recommended that the water drain lines be made from metal since this line may carry very hot water and steam from
21. TEE C 0181 ELBOW C 0520 TEE C 1016 TEE P C 0179 CONNECTOR C0540PLIG C 0631 NIPPLE I RT C 0364 PRESSURE 1 GAUGE 6 0199 CONNECTOR INTERNAL lt 0175 TEE COOLING Coo 2 0337 CONNECTOR NN N 3 C o1 IN C 0179 CONNECTOR C 0123 SILENCER C 0389 SOLENOID VALVE 55 Tc C 0760 VALVE PRESSURE RELEASE C 0022 PRESSURE DUCER 0049 COLLAR C 0050 GLAND C 0049 COLLAR FILTER ASS Y C 0018 TEE C 0181 ELBOW C 0002 1 VALVE C 1091 ADAPTER C 0027 ADAPTER C 0284 ELBOW 3 0049 CAPILLARY TUBE 0 0024 SOLENOID VALVE Yo 81 ELBOW 0 0179 CONN for PUMP saca C 0050 GLAND C 0285 CONNECTOR r AN ELBOW C 0890 ELBOW I I f I I I I AIR TO CYL _ 7777777220 C 0024 SOLENOID VALVE 0689 CHECK gt L C 0055 CONN C 0024 SOLENOID VALVE FILL CYLINDER C 0197 FILTER 3 0013 FILTER HOUSING RL C 0545 TEE 0024 SOLENOID VALVE C 0024 SOLENOID VALVE RESERVOIR COOLING C 0869 REDUCER 0029 BULKHEAD CONNECTOR
22. Volume CEMENT TEST EQUIPMENT INC TULSA OKLAHOMA USA Consistometer Instruction Manual CEMENT TEST EQUIPMENT INC Consistometer User s Manual Revision C 12 24 10 Cement Test Equipment Inc 5704 E Admiral Blvd Tulsa OK 74115 Phone 918 835 4454 Fax 918 835 4475 Table of Contents INTRODUCTION I MAINTENANCE ooccccccccconcnccononononanancnnnnnanos 29 PRESSURE VESSEL AND HYDRAULIC SYSTEM MAINTENANCE 29 CHAPTER 1 POTENTIOMETER MECHANISM POT MECH MAINTENANCE a 31 RBLE OF CONTENTS 525 0 1 SLURRY CUP MAINTENANCE ee 31 INTRODUCTION ann 1 32 CHANGING THE METAL O RING 32 WHAT IS A CONSISTOMETER USED FOR sas 1 CHANGING CLEANING THE HIGH PRESSURE INSTRUMENT DESCRIPTION nennen 1 FILTER ELEMENT een 33 INSTRUMENT SPECIFICATIONS 4 REPLACING THE LOW PRESSURE FILTER INSTALLATION een 5 ELEMENT Eee eu ende 33 USING THE TOUCH SCREEN POTENTIOMETER MECHANISM RESISTOR SOFTWARE meinen 8 REPLACEMENT essen un 6 POTENTIOMETER MECHANISM SPRING WHAT IS A TOUCH SCREEN AND HOW DOES REPLACEMENT oorevovrvvvnvenvvrnvrnrenvvrnvnnvener 35 ITM WORK SATT 8 SERVICING THE INNER MAGNETIC DRIVE USING THE TOUCH SCREEN nennen 8 STRAFEN 36 WHAT CAN YOU DO WITH THE TOUCH SERVICING THE OUTER MAGNETIC DRIVE SCREEN SOFTWARE 9 ROTATOR las 36 THE MAIN 9 REMOVAL OF THE MAGNETIC DRIVE VIEW TEST unna de 10
23. ab exe program not work properly simply delete it and restore Old exe to the original 16 A TOUR OF THE FRONT PANEL CONTROLS Using the USB Memory Stick and Printer The instrument is equipped with a Universal Serial Bus USB port that allows the use of a USB memory stick for mobile storage The memory stick is a flash disk that can be connected to the USB port on the instrument control box and used as an external disk drive Simply insert the memory stick into the USB port and the memory stick will become the D drive Software upgrades may be installed using the memory stick and tests may be archived to the memory stick and transferred to a PC for permanent storage 17 It may be convenient to refer to the piping drawings in Chapter 6 when studying this section The pressure gauge displays pressure in both English and SI units A TOUR OF THE FRONT PANEL CONTROLS Chapter A Tour of the Front Panel Controls Chapter 3 will discuss in detail each front panel control found on both dual and single oonsistormelers All the functions of the consistometer are controlled from the front panel It is very important for the user to have a thorough understanding of each control and it s effect on the operation of the consistometer The front panel controls can be roughly divided into four different sections the hydraulic pressure controls the pneumatic controls the cooling water controls and the electrical electronic cont
24. air lines and drain oil Remove pump and disassemble pump pneumatic side to remove oil If contamination is not too severe you may let the pump stroke under no pressure until the oil is removed This tends to create an oil mist that will fill the entire lab Adjust lubricator to supply less oil The following is a table of frequently used replacement parts along with the CTE part numbers The following parts are used on both the single and dual consistometers except where otherwise noted Shaft Bearing Retainer Potentiometer Slider A 3 0042 fee tl Upper Heater Spreader 3 0035 Lower Heater Spreader 3 0043 44 Calibration Device Assembly Packing Ring Hub Cap Diaphragm Hub Potentiometer Mechanism Assembly Contact Strip Heater Element Low Pressure Filter Assembly Cylinder Leg Cylinder Leg Pressure Vessel Filter Nipple Motor Pulley Motor Shaft Bushing Cylinder Mounting Ring Copper Gasket Slurry Cup Assembly Rotator Sprocket Retainer Magnetic Drive Housing Magnet Shaft Bearing Upper Bronze Bearing Thrust Ring Washer Inner Mag Drive Shaft Cup Table Spacer Lower Bearing Spacer Upper Bearing Spacer Teflon Bearing Rotator Assembly Bearing Stainless Steel Rotator Assembly 7 Plug Handle 2 0022 45 Part Number Shaft Assembly Magnetic Drive Seal Nut Gland 3 8 High Pressure Tubing 46 Belt timing _ Filter Housing low pressure Speed Co
25. ation on servicing the components most commonly in need of repair Changing the metal o ring 1 Refer to drawing 3 0020 Cylinder Assembly in Chapter 6 when changing this o ring Pry the old o ring out using a plastic or soft metal tool so as not to damage the sealing surfaces 2 Coat the new o ring part number C 0061 with a light coating of grease 3 Press the new o ring into the seal groove using your fingers Do not bend or scratch the new o ring 4 Place the plug in the pressure vessel and thread in place until the seal shaft contacts the new o ring 5 Using a rubber mallet or dead blow hammer and light blows begin to close the plug and compress the o ring After three hits with the hammer unscrew the plug part way Repeat this process until the scribe lines on the plug and cylinder are lined up Installation is now complete 32 To minimize the mess place a bucket or cup under the filter housing to catch any oil that might spill 6 Realignment of the witness marks on the plug and cylinder is recommended each time the seats are lapped or if pressure leakage persists In time plug and cylinder threads wear and heat induced flexing of the plug and cylinder require witness mark realignment because the marks no longer represent the actual seating of the seal shaft Changing cleaning the high pressure filter element Refer to drawing 2 0071 Filter Assembly when servicing filter 1 Disconnect the 3 8 inc
26. can be relatively reliable and trouble free provided they are serviced and maintained properly Instruments that are neglected and receive infrequent service or are subject to abuse are certain to cause trouble Pressure Vessel and Hydraulic System Maintenance The metal o ring the pressure vessel o ring seat and the bottom of the seal shaft are the keys to reliable pressure sealing If these components are free from debris and scratches dents reliable sealing will be easily achieved Refer to drawings 3 0020 and 3 0009 in Chapter 6 for information on the cylinder assembly and the hydraulic system 1 Inspect the pressure vessel s metal o ring part number C 0061 and the seat below it after each test and wipe it free of cement particles and other debris Do not use sharp objects such as screwdrivers when removing the metal o ring as it will likely bend or scratch the o ring ruining it Should the seat below the o ring or the seal shaft become pitted or scratched from cement particles 29 If the transfer of the oil from the pressure vessel to the reservoir is slow the filter probably needs to be cleaned or replaced 3 that have migrated into the seal lapping of the seat and seal shaft may be required The cylinder plug threads have been coated with a friction reducing PTFE coating by the factory to help prevent thread seizing and galling However it is still recommended to apply a molybdenum disulfide anti seize com
27. ch should remain OFF until testing begins 4 Program temperature and pressure if unit is so equipped ramp and soak on the touch screen 5 Mix the slurry and fill the slurry cup 6 Place the slurry cup and the potentiometer mechanism pot mech into the pressure vessel and engage the slurry cup to the cup table The motor may be turned on now or at any time using the software selector switch It is not necessary 7 Close the lid on the pressure vessel ES AA lig Insert the thermocouple but do not ee tighten thermocouple fitting 23 8 Turn FILL DRAIN switch to FILL and fill the pressure vessel with oil On a dual consistometer the AIT SUPPLY switch must also be ON When oil begins to run out the top tighten the thermocouple 9 Verify the instrument is reading consistency and start the test using the touch screen 10 Adjust the pressure during the test as desired On units without automatic pressure control releasing pressure may be necessary to prevent an over pressure condition while heating A Brief Example of Stopping a Thickening Time Test The steps listed below are for experienced users who are familiar with consistometer operation 1 2 Stop the test using the touch screen Turn COOLING ON When temperature has cooled below 212 F 100 C open the PRESSURE RELEASE valve and set AIR EXHAUST on DUAL units When the pressure is at zero select DRAIN This will blow the oil from the pressure vessel i
28. eater AC wiring is White Red 12 gauge White Blue 0481 White Orange All other AC wiring is White Purple 18 gauge OWER SUPPLY White Black CONTROL BOX CALIBRATOR PLUG 1 BLUE 2 BLACK Meer 3 YELLO MOTOR SW Jumper 12v for C 0096 C 0075 1 For C 0096 24v for C 0022 Line v5 04 0071 C A GREEN CYLINDER ge D7 D5 He D3 DO A p B WHITE 4 YELLOW ar las laalarl 45 as C 0022 COBEACE INSTRUMENT TRANSDUCER D BROWN BACK PANEL BLACK MEASUREMENT COMPUTING C 1181 GROUNDS 30 33 36 39 49 COM oH 3 P H C 1165 AC C 0629 C 0022 Transducer for 22K amp 40K units 5V IT TE 05 26 09 WIRING SCHEMATIC c 0167 05200 DUAL CONSISTOMETER 05 26 09 5 FROM CON206 WHITE RED GD RESEVOIR T C C 0096 Transducer for 20K units CEMENT TEST EQUIPMENT INC BROWN A CONNECTOR RIGHT SIDE a 05 26 09 a 03 0300 1 ELE _ C 0377 MOTOR Revised 12 10 10 JPB 6 05 26 09 SPEED POT MEASUREMENT COMPUTING BOX OUTPUTS IO O 4 OUTPUTS 0 HEATER 1 COOL CYLINDER 2 COOL RESEVOIR 3 PUMP 4 PRESS CONTROL 5 0IL FILL PRESS RELEASE 6 AIR TO CYLINDER 7 M
29. ee if yours does control box in lieu of a printer Test data may be uploaded to the USB drive and then transferred to a PC for archival storage Refer to Chapter 2 Using the Touch Screen Software for more information on printer and USB drive An optional keyboard may be connected to the control box at this time Before attempting to operate the instrument it is recommended that the operators read the remainder of the manual and study the drawings that appear in the Drawings Schematics section of this manual to become familiar with the consistometer operation A TOUR OF THE FRONT PANEL CONTROLS Chapter Using the Touch Screen Software What is a touch screen and how does it work Touch screens were created to provide users with an easy to use interface This allows the user to input and view data without a keyboard or mouse The touch surface is able to detect contact and send position information back to the processor Using the touch screen has the same result of using a mouse to point and click One mouse click is accomplished by one touch of the screen A double click is achieved with two quick touches With this standard method of input no special software is required to utilize the screen Using the Touch Screen Most any object may be used on the touch screens Experimentation will quickly show which objects will activate the screen and which will not It is important to note the touch surface does NOT use pressure to de
30. ess the C 0108 Roll Pin out of the 3 0071 Thrust Ring and remove the thrust ring Take care not to bend the shaft Replace the thrust ring if badly worn 4 The upper 3 0072 Bronze Bearing may now be removed Replace if badly worn 5 Remove the C 0130 Snap Ring Replace is corroded or damaged The 3 0073 Carbon Bearing or the 3 0073 1 Bronze Bearing may now be removed Replace if badly worn 6 Remove the hex head screw and 3 0074 6 Washer from the other end of the shaft to remove the second 3 0073 or 3 0073 1 Bearing Replace if badly worn 7 Assemble in reverse order of disassembly Servicing the Outer Magnetic Drive Rotator Refer to drawing 3 0063 Magnetic Drive Assembly in Chapter 6 for servicing all magnetic drive components 36 9 CAUTION Make certain that the power to the instrument is disconnected before servicing the magnetic drive rotator The rotator is very close to the heater terminals and severe shock or electrocution could occur if contact is made with a live heater circuit Loosen two of the three setscrews on the 3 0067 Outer Magnetic Drive Support The 3 0066 Outer Magnetic Drive Rotator Assembly will fall off It may be necessary to loosen the 3 0061 Magnetic Drive Sprocket to completely remove the rotator CAUTION The inner shaft is composed of extremely powerful magnets If these magnets are allowed to get too close to steel objects the magnetic force may cause injury or damage to the shaft Also kee
31. g the slurry cup supplies heat to the pressure chamber A centerline thermocouple is provided for determining the temperature of the cement slurry The slurry cup is rotated through the use of an electric motor and a magnetic drive unit The rotational speed of the slurry cup is variable between 25 and 250 rpm to allow the user to study slurries at speeds other than the API prescribed speed of 150 rpm The consistency of the cement slurry is measured through a potentiometer mechanism commonly referred to as a pot mech The potentiometer is coupled with a torsion spring to resist the rotating force of the paddle The rotational force is proportional to the consistency of the cement slurry and is measured through the potentiometer resistor as the spring deflects under load The consistency is displayed on the plot generated by the data acquisition system The consistency values are recorded in Bearded Units of consistency Bc Bearden units are defined in API Specification 10 The consistometer is equipped with one or two devices for post test cooling of the instrument The first is an external cooling coil attached to the pressure vessel After completion of the test cooling water may be circulated through this coil to cool the pressure vessel The instrument is optionally equipped with an oil reservoir cooling coil as well Our temperature controller and data acquisition system are so easy to operate you won t even need a manual We
32. h high pressure connections and remove the 2 0071 Filter Assembly Secure the 2 0072 Filter Housing in a vice and remove the 2 0074 Seat Retainer Compressed air may be forced through the 2 0076 Filter Element to remove the debris attached to the filter The 2 0076 Filter Element may also be unscrewed from the 2 0075 Filter Nipple and cleaned with solvent or a weak acid solution Thread the filter onto the filter nipple Install the filter element and 2 0073 Filter Seat into the housing and secure tightly with the seat retainer Install the filter back in the instrument If transferring the oil from the pressure vessel to the reservoir is still slow replace the 2 0076 Filter Element Replacing the low pressure filter element 1 2 3 Make certain all valves are closed Open the AIR EXHAUST valve Locate the blue low pressure oil filter housing 33 4 Remove the nut on the top of the filter housing The filter bowl and C 0102 filter element will come off 5 Replace the filter element with a new element 6 Inspect the C 0101 gasket and replace if necessary 7 Replace the bowl and filter element and install the nut It may appear that the filter element is too long but the element will be compressed as the nut is tightened which separates the filtered oil from the unfiltered oil 8 Check for leaks Potentiometer Mechanism Resistor Replacement Refer to drawing 2 0050 when replacing the 2 0062
33. his is an equivalent of 9 Bc On the touchscreen in the box labeled LOW DATA POINT input 9 on the touchpad Select SAVE LOW VALUE 8 Place 400g of weights on the weight hanger This is the equivalent of 100 Bearden Units of Consistency Bc On the touchscreen in the box labeled HIGH DATA POINT input 100 on the touchpad Select SAVE HIGH VALUE 9 The touch screen should indicate 100Bc in the CALIBRATED VALUE display 10 Remove some weight and check the CALIBRATED VALUE If the values are correct calibration is complete If the values are incorrect repeat steps making adjustments to Potentiometer Mechanism as required Refer to table 4 1 for weight to Bc conversions for your pot mech 27 Table 4 1 Consistency as a function of Weight vs Torque By applying WEIGHT 9 CONSISTENCY Bc additional weights 0 4 between 0 and 50 9 400g and plotting 100 22 consistency 150 35 display as a 200 48 function of applied 250 61 weight the 300 74 linearity of the 350 87 potentiometer 400 100 mechanism may be assessed Based on the equation from API Spec 10 Section 8 2T 78 2 20 02 Bc T Torque g cm Bc Bearden units of slurry consistency 28 Chapter Maintenance Servicing and Troubleshooting This chapter contains information about the necessary periodic maintenance of the instrument as well as common service and troubleshooting guuclehnes Maintenance Consistometers
34. ic oil and faster turnaround between tests The cooling water controls consist of a COOLING WATER switch and a RESERVOIR COOLING switch The COOLING WATER switch allows water to flow through the cooling jacket surrounding the pressure vessel This valve should be turned on at the completion of a test to cool the pressure vessel Alternatively software can be used to cool the cylinder automatically 20 CTE is the first company to offer variable speed as a standard feature on all its pressurized consistometers A TOUR OF THE FRONT PANEL CONTROLS The RESERVOIR COOLING switch allows water to flow through the internal cooling coils in the oil reservoir to cool the hydraulic oil This valve may be opened at the completion of a test to or it may be opened during a test if the oil in the reservoir becomes too hot or if it is desired to keep the oil cool to reduce turnaround time for the next test Other Electrical and Electronic Controls Additional primary electrical electronic controls may include the POWER HEATER MOTOR and TIMER switches the pump controls and motor speed adjustments The primary display is the touch screen These controls are discussed in detail below The switch labeled POWER controls electrical power to the entire instrument Nothing else is operable if this switch is not on If available switches labeled HEATER and MOTOR can be used to disable power to the heater and motor Under normal conditions these
35. inder will be emptied of oil Under DRAIN conditions the cylinder must be closed When the selector is in the OFF position the instrument is idle and cannot be run Note for DUAL Consistometer If only one cylinder is to be drained of oil the AIR EXHAUST must be active During the draining process the other side of the instrument cannot pump until AIR SUPPLY is turned back on after fully draining the non active cell The Pneumatic Controls The pneumatic section consists of the AIR PRESSURE gauge the air pressure REGULATOR the PUMP AIR PRESSURE gauge and the AIR SUPPLY AIR EXHAUST valve DUAL consistometer only The components in this section are used to fill and drain oil from the pressure vessel and to power the air driven hydraulic pump that applies pressure to the sample The AIR PRESSURE gauge indicates how much air pressure is being supplied to the instrument Air at the pressure indicated on the gauge is Supplied to the oil reservoir to force oil out through the dip tube s and into the pump inlet The part number for the AIR PRESSURE gauge is C 0364 If there is no pressure indicated on this gauge the pump will not operate 19 If the PUMP AIR PRESSURE drops off significantly when the pump is operating an air line may be blocked or the compressor may be insufficient to deliver the volume of air required A TOUR OF THE FRONT PANEL CONTROLS The air pressure REGULATOR is used to control the air pressure to the a
36. input by simply touching on the ADD EDIT boxes and entering data using the pop up keypad Additionally repeat customers can be saved in the Customer menu by pressing NEW next to the Customer menu and inputting a customer name The customer can then be selected from the drop down Customer menu box The entire profile of any test can be easily saved and recalled by selecting SAVE PROFILE after the profile has been completely configured To recall a saved profile simply select it from the SAVED PROFILES drop down menu and press OK Customers and profiles can be deleted from memory by pressing the RED DELETE BUTTON next to either Customer or Profiles Be sure to have the profile you would like to delete selected at the time you press the DELETE button Test parameters can be deleted or changed by selecting the parameter and touching the EDIT button 14 A TOUR OF THE FRONT PANEL CONTROLS START TEST Once your instrument is properly configured and a test has been entered in the TEST SETUP section You may begin testing by selecting the START TEST button from the main menu LIVE TESTING SCREEN Once a test has begun a real time display of current values will be presented The user may view a live chart at any time by pressing the LIVE CHART tab button located at the top of the screen Printing can be done at any time by selecting the ADVANCED CHART amp PRINTING OPTIONS button Please note that a printer must be connected to the instrument befo
37. ir driven hydraulic pump Higher hydraulic pressures require higher air pressures To adjust the pressure of the air supplied to the pump pull the knob on the regulator out to unlock it Turn the regulator knob clockwise to increase the pressure and counterclockwise to decrease the pressure When the adjustment is finished push the knob in to lock it in place if desired The part number of this regulator is C 0021 The PUMP AIR PRESSURE gauge shows the pressure of the air delivered to the pump The pressure may be changed by adjusting the air pressure REGULATOR as described above The part number of this gauge is C 0364 DUAL UNITS AIR SUPPLY AIR EXHAUST switch This switch accompanies the FILL DRAIN Any time you wish to FILL a cylinder or RUN a test the AIR SUPPLY must be ON Any time you wish to drain a cylinder you must select AIR EXHAUST to relieve air pressure from the oil reservoir If only one cylinder is to be drained of oil the AIR EXHAUST must still be active During the draining process the other side of the instrument cannot activate the pump until AIR SUPPLY is turned back on Do this immediately after fully draining the non active cell The Cooling Water Controls The cooling water controls are used to cool the cylinder and oil reservoir at the completion of a test The CTE pressurized consistometers are optionally equipped with an industry first internal cooling coils in the oil reservoir for quick cooling of the hydraul
38. is greater than 200Q replace the resistor Replace Inspect and replace if necessary Check electrical continuity between ground pin and cylinder If continuity does not exist replace ground pin Check electrical continuity between the two yellow connections on the potentiometer If no continuity exists replace the potentiometer Check electrical continuity between contact pins and cylinder If continuity exists replace contact pin This does not apply to the ground pin which always has continuity with cylinder Check fuses inside electrical box Replace any that are blown Check heater terminals for loose Symptom Temperature display is erratic Temperature displays and unusually high number gt 1500 F Oil comes out pump muffler Pump may or may not stroke Cause Faulty heater Faulty solid state relay Faulty thermocouple Loose connection in thermocouple wiring Open circuit in thermocouple Open circuit in thermocouple circuitry AIR TO CYLINDER valve has been opened while cylinder is pressurized flooding the air lines and pump pneumatic side with oil Air lubricator is putting too much oil in the pump air 43 Remedy wires and reconnect if necessary Replace Replace Replace thermocouple Check for loose wiring and correct if necessary Replace thermocouple Check thermocouple circuitry for open circuits or loose connections Correct if necessary Remove
39. k that the wiper is making contact with the potentiometer resistor throughout it s entire length of travel Slurry Cup Maintenance Refer to drawing 3 0030 in Chapter 6 for a section view of a slurry cup 1 Check the slurry cup after every test to be certain the threads are not contaminated with cement Lubricate the threads with grease prior to the start of every test It is recommended that hardened cement slugs be pressed out rather than pounded out with a hammer Pressing tends to cause less damage When pressing the slug out be careful not to damage the paddle shaft point or the paddle itself If the slug is not pressed out straight it may cause the cup sleeve to become oval and prevent the threaded closures from threading into the sleeve 31 3 Periodically disassembly the diaphragm hub and clean any cement from the Teflon o rings Replace the o rings if they are badly worn 4 Check the rubber diaphragm for signs of brittleness or cracking Replace if necessary 5 Check the point on the bottom of the paddle shaft Replace it if it is worn to the point that the paddle rubs on the bottom of the slurry cup Check to see that the paddle shaft is not excessively worn where the shaft extends through the diaphragm hub Replace if wear is excessive 6 Check the slurry cup seal plug for wear Replace it if it is worn to the point that the paddle rubs on the bottom of the slurry cup Servicing This section provides inform
40. n locked in place prior to shipment to prevent the weight from damaging the swivel arm Prior to removing the plug from the pressure vessel loosen the bolt holding the counterweight in place until the counterweight is free to move The control box should be connected to the instrument by connecting the 5 pin power cord to the back of the instrument frame as well as the supplied USB cable The instrument will not operate without this USB cable connected from the computer to the machine 6 There are two power connectors on the back of the electrical box An uninterruptible power supply UPS may be connected between these power connectors to maintain consistometer operation during short power outages or interruptions If an UPS is not used a jumper cord must be connected between these two connectors or the unit will not power up An appropriate jumper cord was included with the consistometer accessories Some instruments f a printer is included with the instrument it may be connected to the especially in rear of the consistometer Connect the USB connector on the printer overseas cable to any USB input on the control box The printer must also be locations have connected to an A C power outlet One is supplied on the back of the printer power instrument for this Refer to the printer documentation for power connectors requirements A USB flash drive Drive may also be connected to the located on the rear on the electrical box Check to s
41. not installed the instrument will be equipped with a C 0076 switch that is used to turn the pump on and off If the pressure control option is installed the unit will be equipped with a three position switch labeled ON OFF and AUTO When the switch is in the OFF position the pump will not run When the switch is in the ON position the pump will run until turned to the OFF position When the switch is in the AUTO position the pump will be turned on and off by the pressure control software The part number for the three position switch is C 0302 This completes our tour of the front panel components The operation of these components will be discussed in greater detail along with examples in Chapter 4 Operation and Calibration 22 A light coating of grease on the threads is important to prevent cement from filling the threads Chapter Operation and Calibration Chapter 4 will discuss in detail the steps required to run a thickening time test and calibrate the instrument Examples will be provided men necessary A Brief Example of Running Thickening Time Test The steps listed below are for experienced users who are familiar with consistometer operation 1 Close the PRESSURE RELEASE valve if supplied 2 Turn the POWER switch to the ON position 3 Turn the MOTOR and HEATER switches to the ON position if available CAUTION On consistometers with serial number below 207 and Small Footprint units the HEATER swit
42. nto the oil reservoir You will hear AIR escaping from the rear of the instrument once the cylinder is empty of oil At this point you must turn the FILL DRAIN switch to OFF Open the RESERVOIR COOLING valve to cool the oil in the reservoir if equipped and desired 24 All CTE slurry cups are tapered with the large end at the top This makes it easier to press the cement plug out of the slurry cup 6 When the cylinder is cool enough remove the slurry from the slurry cup before it sets and becomes too hard Press the cement plug out from bottom to top Calibration If the instrument The potentiometer mechanism thermocouple and pressure is within tolerance after several calibration checks extend the calibration interval If it is out of tolerance shorten the interval transducer optional should be recalibrated on a regular basis It is recommended that the thermocouple and pressure transducer if so equipped be calibrated at least annually and anytime new thermocouples or pressure transducers are installed The potentiometer mechanism pot mech should be recalibrated whenever the spring contact arm or resistor is adjusted or replaced Higher operating temperatures generally require more frequent recalibration Temperature Calibration Procedure Temperature may be calibrated using the Temperature Calibrator CTE part C 0373 1 With Instrument ON and CementLab running select INSTRUMENT SETUP CALIBRATE
43. ntrol Gear 47 Description 48 THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY DE REVISIONS CEMENT TEST EQUIPMENT ANY REPRODUCTION IN PART OR WHOLE WITHOUT RE DESCRIPTION DATE APPROVED THE WRITTEN PERMISSION OF CEMENT TEST EQUIPMENT IS PROHIBITED 9 0 D D N EJ zZ LL ALL DAR AWAY 0 IR fel T T gt Zn VG Ls eh I 25 ge zu N 10 AV a E Z TZ GGG GET T Uy AG ED A ee A a A Yi AU O y y ELO Ness ES ITEM NO QTY PART NO DESCRIPTION CYLINDER PLUG SEAL RING O RING CONTACT PIN SECTION A A SCALE MAGNETIC DRIVE ASS Y SLURRY CUP ASS Y POTENTIOMETER MECHANISM ASS Y HANDLE THERMCOUPLE HEATER GROUND PIN NOT SHOWN O RING NOT SHOWN UNLESS OTHERWISE SPECIFIED CAD GENERATED DRAWING DIMENSIONS ARE IN INCHES T MANUALLY UPDATE TOLERANCES ARE CEMENT TEST EQUIPMENT INC DATE FRACTIONS DECIMALS ANGLES APPROVALS XXX 2 005 DEP Fe CCD 3 17 98 gr CCD 3 I7 98 CYLINDER ASSEMBLY RESP ENG CCD 3 17 98 MFG ENG SIZE NO REV DE 3 17 98 0 8 1 CAD FILE SHEET 1 OF FINISH 8 7 5 4 3 2 1 8 7 6 THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROP
44. p the shaft away from metal filings as they will adhere to the shaft and cause premature wear To remove the 3 0056 Upper Bearing remove the C 0090 Retaining Ring and slide the bearing out Expect for excess wear and replace if needed To remove the C 0087 Lower Bearing remove the C 0091 Retaining Ring and slide the bearing out Inspect for excessive runout or rough operation and replace if necessary Removal of the 3 0052 Inner Magnet Sleeve is usually not necessary and is not recommended Assembly is the reverse of disassembly Removal of the Magnetic Drive Housing Refer to drawing 3 0063 Magnetic Drive Assembly in Chapter 6 for servicing all magnetic drive components CAUTION Make certain that the power to the instrument is disconnected before servicing the magnetic drive rotator The rotator is very close to the heater terminals and severe shock or electrocution could occur if contact is made with a live heater circuit Loosen two of the three setscrews on the 3 0067 Outer Magnetic Drive Support The 3 0066 Outer Magnetic Drive Rotator Assembly will fall off 37 Use care when working near the heater terminals They are easily bent or broken CAUTION The inner shaft is composed of extremely powerful magnets If these magnets are allowed to get too close to steel objects the magnetic force may cause injury or damage to the shaft Also keep the shaft away from metal filings as they will adhere to the shaft and ca
45. pound to the threads periodically The high pressure filter is located in the 3 8 inch stainless steel pressure lines between the pressure vessel and the pressure release valve This filter protects the pressure release valve air operated valve if equipped and capillary tube if equipped from cement particle damage and or blockage It also prevents cement particles from being carried into the oil reservoir This filter must be disassembled and the filter element cleaned or replaced periodically The mineral oil in the reservoir should be drained and replaced when it becomes dirty The low pressure oil filter element part number C 0102 should also be replaced periodically These filters are located in a blue housing The oil reservoir is equipped with drain valve on the bottom and a filling plug at the top To thoroughly clean the reservoir the entire unit may be taken out of the instrument and the bottom removed Mineral oil may be conveniently added by pouring oil into the pressure cylinder and transferring it to the oil reservoir The mineral oil supplied with the instrument has an open cup flash point of approximately 188 C 370 F The magnetic drive should be flushed with clean solvent periodically and whenever cement spills into the cylinder or particles contaminate the drive If cement enters the magnetic drive it will cause the bearings to wear quickly If the worn bearings are not replaced it may cause the inner magnetic dri
46. predictable slurry density volume viscosity compressive strength fluid loss gas migration and thickening time Slurry thickening time or the time a slurry remains pumpable in a well is one of the most critical properties in designing cement slurry A predictable thickening time is desired while maintaining the other specific properties of the cement slurry The thickening time can be measured in a laboratory by testing a sample of the cement slurry in a pressurized consistometer The elapsed time between initial application of pressure and temperature on the slurry sample and occurrence of a predetermined value of consistency usually 100 Bearden Units Bc is the thickening time for the sample at the particular specification test schedule The typical test schedules are listed in API Specification 10 on Oilwell Cements Instrument Description The Model 40 600 Pressurized Consistometer is able to test cement slurries at temperatures up to 600 F 316 C and pressures as high as 40 000 psig 276 MPa The Model 25 400 has operating limits of 400 F 204 C and 25 000 psig 172 MPa The model 22 400 has operating limits of 400 F 204 C and 22 000 psig 151 MPa The consistometer Slurry Cup Assembly part number 3 0030 or 2 0030 uses a rotating cylindrical slurry cup and a stationary paddle assembly enclosed in a pressure vessel Pressure is applied to the vessel using mineral oil and an air driven hydraulic pump A tubular heater surroundin
47. quipped with automatic pressure control Slurry cup rubs on heater or heater spreader Slurry cup will not turn Erratic motor speed control Cause pump muffler oil reservoir ran dry If oil is coming from pump muffler the pump high pressure seal is probably worn out Stainless steel lines 3 8 inch are plugged with cement If valves cannot be heard exhausting air the problem is a faulty solenoid valve on the air operated valve If valves can be heard exhausting air the problem is most likely a plugged capillary tube connected to the exit port of the valve Heater does not sit flush with bore of pressure vessel or heater spreaders missing Magnet drive bearings are worn Missing pin on slurry cup base Magnetic drive severely contaminated with cement Blown fuse on motor control board Faulty motor or controller Broken drive belt Magnetic pickup holder has come loose Worn out bearings in magnetic drive outer rotator 41 Remedy Overhaul or replace pump Remove lines and inspect for blockage Replace any that are plugged Repair or replace solenoid valve Replace capillary tube Bend heater to sit flush with bore of vessel and add heater spreaders Check bearings on inner magnet shaft and replace if necessary Replace pin or base Remove magnetic drive plug and inner magnet shaft and clean magnetic drive thoroughly Check fuses on motor control board located in
48. re trying to print This button will also enable the user to view detailed test information and streaming numerical data The user can also create custom header and footer segments of the printed plot Pressing the EXIT button returns the user to the RUN TIME MENU shown below arena y Tager ar 0 0 on HEATER Im 00 00 HIDA lt Set Pare Be Be 1 J 9 te some options not shown Temperature control may be toggled between AUTO and MANUAL AUTO is recommended Note that establishing a set point significantly different from the current temperature may cause large overshoots in temperature set point If manual temperature control is required it is recommended that it be increased slowly in 2 5 degree increments The instrument is equipped with an automatic consistency shutdown alarm Use the up down arrows to select the consistency value at which the alarm should occur If the Auto Shutdown feature is ON the instrument will automatically stop the test when the indicated alarm value is reached In addition to stopping the test automatic 15 A TOUR OF THE FRONT PANEL CONTROLS shutdown will also turn the heater and motor off and the cooling water on Note that the Auto Shutdown Alarm is in addition to the alarm values entered in TEST SETUP that are printed with each plot STOPPING A TEST To stop the current test the user must press the STOP TEST button on the RUN TIME MENU screen Once the test has been stopped no f
49. rols This chapter will discuss each section in detail The Hydraulic Pressure Controls This section consists of the following controls the PRESSURE gauge the PRESSURE RELEASE valve and the FILL DRAIN switch Components that make up this section are used to control the flow of oil used to pressurize the cylinder and to display the cylinder pressure The PRESSURE gauge is used to display the pressure inside the pressure vessel The part number for the pressure gauge is C 0465 The PRESSURE RELEASE valve is used to release pressure from the pressurized cylinder The PRESSURE RELEASE valve must also be fully opened to remove oil from the cylinder If it is necessary to fill only one pressure vessel of a dual consistometer the 18 The pressure gauge displays pressure in both English and SI units A TOUR OF THE FRONT PANEL CONTROLS PRESSURE RELEASE valve on the unfilled side must be closed or oil may back up into the cylinder through the oil return lines The part number for the PRESSURE RELEASE valve is C 0005 1 The FILL DRAIN switch is used to control the flow of oil into the pressure vessel When the switch is set to FILL and there is air pressure on the instrument oil will begin to flow into the cylinder Ensure that the lid is closed and thermocouple fitting is loose to allow air to escape while filling When the switch is set to DRAIN the PRESSURE RELEASE valve is open and air is exhausted from the instrument the cyl
50. s Wows sl 7 me Z Z AL ES SECTION A A SCALE 2 1 UNLESS OTHERWISE SPECIFIED CAD GENERATED DRAWING DIMENSIONS ARE IN TOLERANCES ARE FRACTIONS DECIMALS ANGLES APPROVALS DATE MATERIAL FINISH FSENG CCD 10 22 97 SHE DWG no ee CCD 10 22 97 scale 1 CAD FILE wer POWER ma 90024 3 c 0024 HO c 0024 230 VOLTS 50 AMPS 50 60 HZ C 0024 6 4 C 1304 AIR RESVOIR AIR TO CYL PUMP COOL 2 WAY SUPPLY away COOL 2 WAY soLENOID 2 WAY en FILLIDRAIN CYLINDER EXHAUST 3 i SWITCH 8 e OLFILL amp OFF NO SOLENOID ACTIVE DRAIN AR2CYL GREEN 10 RED LOAD LINE TO RIGHT SIDE gt gt Bum 93 RED COOL SWITCH AIR SUPPLY RES COOL C 0489 SWITCH C 0489 SWITCH C 0489 Se YELLOW L o YELLOW POWER SWITCH TERMINAL BLOCK C 0472 cat 6 0075 2 AUTO OFF ON 18 GAGE YELLOW 1 e e SSR RO 2 PUMP SWITCH C 0132 RED Q e Q C 0478 2 SSR BLOCK a YELLOW 18 C RED 12 YELLOW 12 C 0585 FUSE BLOCK pes HT
51. side electrical box Replace as necessary Replace drive belt Check magnetic pickup holder on bottom magnetic drive and tighten if necessary Check rotator for excessive runout or wobble with motor running Remove rotator and inspect bearings Replace if necessary Symptom Consistency display always indicates Zero Consistency meter always displays approximately 150 Bc Heater will not get hot Cause Blown fuse Measure voltage between blue and yellow contact pins If voltage is zero the 15 VDC power supply has failed or there is an open circuit in the blue or yellow wires Broken potentiometer mechanism resistor Broken or corroded potentiometer connecting strips Broken severely worn or corroded contact springs Broken or corroded ground pin Faulty CONSISTENCY SPAN potentiometer Shorted contact pin Blown fuse Loose heater wire 42 Remedy Replace fuse Check the power supply output If output is approximately 15 VDC use and ohm meter to check for open circuits in the yellow or blue wires Isolate and correct If power supply voltage is zero when the yellow and blue wires are removed replace the power supply It the power supply voltage is 0 VDC when the wires are connected but 15 VDC when the wires are disconnected there is a short circuit in the yellow wire With the potentiometer out of the instrument check the resistance of the potentiometer resistor If it
52. sired temperature ramp is displayed for confirmation Press ACCEPT to save ramp or CANCEL to exit without saving AcceptChange HESITATION SQUEEZE On units equipped with the hesitation squeeze option it may be accessed using the button labeled Hesitation Squeeze Pressing this button will bring up the following screen This allows a very random schedule to be programmed using user selected timing intervals 13 A TOUR OF THE FRONT PANEL CONTROLS Select Motor Speed Bc select the empty box under Run Time and enter the hesitation start time in minutes using the touch pad a right The Start Time is the elapsed time from the beginning of the test to the first hesitation squeeze start Select Next Ramp to enter first stop The screen will re initialize and you can select STOP for motor speed and enter desired amount of time for STOP segment in Run Time box Selecting Next Ramp again will allow you to enter run time after first STOP segment If you wish to repeat the schedule for the remainder of the test simply select AUTO REPEAT after 3 segments have been entered Bc STOP Bc An infinite number of sequences can be input Select SAVE to save or Cancel to exit without new schedule A preview of the schedule will be shown for approval OPTIONAL PARAMETERS AND PROFILE SAVING Many optional parameters can be saved in your test profile from the Test Setup screen These include names for Well Cement District etc and can be
53. spring Replace potentiometer slider Loosen the three spring adjuster clamp screws on underside of the frame but do not remove the screws Rotate the 2 0053 Spring Adjuster until the potentiometer slider lines up with the front contact strip Tighten adjuster clamp screws Rotate potentiometer slider by hand Assure that slider makes contact with the resistor during its entire range of motion If necessary adjust slider by bending it up or down Replace shaft bearing retainer and check the potentiometer mechanism with a calibrating device 35 It is sometimes necessary to remove the 3 0065 Plug Assembly from the bottom of the 3 0062 Magnetic Drive Housing The oil in the magnetic drive can create a vacuum that makes removal of the inner shaft difficult especially if the housing is contaminated with cement Servicing the Inner Magnetic Drive Shaft Refer to drawing 3 0063 Magnetic Drive Assembly in Chapter 6 for servicing all magnetic drive components 1 Pullthe 3 0070 Inner Magnet Shaft Assembly out through the top of the pressure vessel CAUTION The inner shaft is composed of extremely powerful magnets If these magnets are allowed to get too close to steel objects the magnetic force may cause injury or damage to the shaft Also keep the shaft away from metal filings as they will adhere to the shaft and cause premature wear 2 Unscrew the cup table from the magnet shaft assembly 3 Pr
54. t closed tightly PRESSURE RELEASE or AIR TO CYLINDER valves worn out Metal o ring C 0061 is scratched or dented O ring sealing surfaces and or seal shaft are worn pitted or scratched Valve open severe leak blown rupture disc Pressure vessel has trapped air Oil reservoir is empty OIL SUPPLY valve is closed dual consistometer only AIR SUPPLY valve not opened or air not connected to instrument Severely clogged low pressure filter Faulty pump check valve No air supplied to air operated valve if so equipped If not oil is coming from 40 Check fittings for leaks and tighten fittings Heater ferrules contact pins and magnetic drive housing are also possibilities Close valves tightly Replace valve stem or entire valve PRESSURE RELEASE valve is most likely to wear out Replace o ring Lap o ring sealing surfaces A lapping kit is available from CTE Locate problem and correct Open thermocouple connector slightly and release trapped air Fill reservoir with oil Open OIL SUPPLY valve Connect air supply and open AIR SUPPLY valve Replace low pressure filter element Clean and or overhaul pump outlet check valve Check air lines leading to valve Check valve solenoid valve Restore air supply Add oil to reservoir Symptom maintains pressure to a certain level than then stops Pressure cannot be released Air operated valves will not release pressure on units e
55. tect input A light touch is all that is needed In addition sharp instruments such as pencils pens screwdrivers etc should not be used as they may damage the touch surface A pen like touch stylus has been included in your accessories to use if desired A TOUR OF THE FRONT PANEL CONTROLS What can you do with the touch screen software The purpose of the touch screen is to provide the user with a single interface to the instrument Temperature control motor control instrument setup and current test data are accessed through the touch screen This eliminates the need to individually program controllers or other off site PC software to begin running a test Additionally the touch screen allows the user to access current information at the instrument during a test Each instrument is complete and requires no additional software or hardware to function The Main Menu The main menu is starting point for the instrument From here users may start new tests set up test parameters setup instrument parameters or view an old test Also located on the main menu is the current reading for temperature consistency and pressure if so equipped As noted in the instructions on the screen all the user need do is touch a button to begin A TOUR OF THE FRONT PANEL CONTROLS VIEN TEST Pressing this button opens the test viewer software and allows you to select any test file available INSTRUMENT SETUP INSTRUMENT SETUP This but
56. terials that would interfere with the operation of the instrument before powering the instrument Some components such as touch screen LCD monitors if applicable and computer control modules are be removed from the instrument prior to shipment and may be in a separate container to prevent damage These devices must be reinstalled before operating the instrument Locate the box containing the touch screen monitors and remove them from their shipping containers While standing at the rear of the instrument align the four mounting holes in the black monitor housing with the four holes in the front panel With the monitor screen facing the front of the instrument secure the monitor to the front panel with the four screws provided Connect the 15 pin video and USB cables from the monitor to the back of the control box You must also connect the power cord from the monitor to an A C outlet on the back of the instrument If the instrument is equipped with auxiliary stand alone temperature controllers they must be removed from their shipping containers and installed into the sleeves in the front panel Simply slide the controllers into the sleeves and snap them into place In order to protect the internal mechanisms of the pressure gauges the needles are fixed in place with a screw and a small metal bracket This bracket must be removed prior to using the instrument On 25 400 and 40 600 consistometers the counterweight in each swivel arm has bee
57. time to time Electrical connections are made using the twist lock receptacle on the rear of the instrument A 50 A female plug part number C 0524 is supplied with each dual consistometer and a 30 A female plug part number C 0211 is included with each single consistometer Please observe the following precautions when making the wiring connections e A qualified installer should do the wiring in accordance with local electrical codes e The instrument should be securely connected to a separate earth ground The ground wire must be larger in diameter than the supply conductors An 8 gauge minimum ground wire is recommended for a dual consistometer and a 10 gauge minimum ground wire is recommended for a single consistometer e An 8BC or larger fire extinguisher to fight electrical and oil fires should be placed within 50 feet of the consistometer Before operating the instrument it is a good idea to check the bottom of the consistometer for loose screws or bolts that may have loosened and or fallen out during shipment This is particularly true for overseas shipments Exposed metal surfaces on the seal shaft sealing nut and cylinder are coated to prevent rust The coating should be removed with a hydrocarbon based solvent before operation of the instrument Certain components are supported during shipment with wooden blocks foam padding and plastic ties to prevent damage Open the front doors and remove all the packing ma
58. ton takes the user to the Instrument Setup Screen From this screen the user may calibrate temperature consistency gel strength optional and pressure optional Additionally the user can ARCHIVE all tests on the consistometer to the USB memory stick or network location This function will copy all tests in current C CTE data folder and paste them into the selected folder networked drive or USB An AUTO EXPORT function allows the user to select a folder or network storage where any test will be automatically copied to after the test is stopped CALIBRATE TEMPERATURE CALIBRATE PRESSURE This button allows the user to select the calibration routines Ent w Value c SAVE LOW VALUE When this screen appears connect a temperature calibrator to the thermocouple input on the instrument Enter a lower limit temperature value on the calibrator Touch the Enter Low Value parameter box and then enter the correct temperature value for the Low Data Point using the touchpad at the right The raw value is the signal read directly off the I O hardware and it should change as the calibration signal changes 10 A TOUR OF THE FRONT PANEL CONTROLS When the low data point has been entered press the SAVE LOW VALUE button The user can now enter the high data point on the calibrator and then again on the touchscreen as before The raw value should be different for the low and high data points or there will be a computation error After the
59. urther data will be logged and no further temperature or pressure control will be provided The software will save the current test in a file on the instrument s local hard disk The default location is C CTE Tests If auto shutdown is enabled the test will be stopped when the Consistency Alarm value has been reached This action has the same effect as the user pressing the STOP TEST button however it also turns the motor and heater off and the cooling water on Note that there is a 5 10 second delay from the time a consistency alarm is triggered until automatic shutdown occurs This is to prevent noise or spikes in the consistency signal from triggering automatic shutdown prematurely Software Upgrades From time to time CTE makes software upgrades available that provide increased functionality or problem fixes Generally the only file that needs to be upgraded is CementLab exe It is located in the c Program Files CementTestEquipment folder If it is necessary to install an updated CementLab exe file it may be copied from the USB memory stick It may also be copied over a network if the instrument is connected to one To copy the file from a memory stick put the new file on the memory stick rename the old CementLab exe file to Old exe and copy the new file into the proper folder using Windows Explorer which is accessible from the start menu or My Computer icon The memory stick will generally be the D drive Should the new CementL
60. use premature wear 2 With a spanner wrench loosen the 3 0064 Lock Ring is found in the recessed hole in the bottom of the pressure vessel 3 Push the 3 0062 Magnetic Drive Housing up through the pressure vessel bore and out the top It may be necessary to gently tap the housing with a hammer to break it loose if it is cemented in place If cement contamination is severe cement may have to be removed out through the bore of the pressure vessel before the housing can be removed 4 Replace the C 0111 Teflon o ring prior to assembly 5 Assembly is the opposite of disassembly Heater Replacement The 3 0022 Heater should be replaced if a hole burns through the sheath or if the heater fails to heat The replacement steps are listed below CAUTION Make certain that the power to the instrument is disconnected before servicing the heater Severe shock or electrocution could occur if contact is made with a live heater circuit 2 Remove the 3 00 Upper Heater Spreader from the pressure vessel bore 3 Remove the 3 002 Contact Pin Shield 4 Remove wites from the 3 0027 Contact Pins and the 3 0029 Ground Pin and note to which pin each wire is connected 5 Remove the 3 00 Lower Heater Spreader 6 Remove the 3 0066 Magnetic Drive Rotator Assembly as described above 7 Remove wires from heater terminals 38 A deep socket 8 or a piece of 3 8 inch tubing 9 may be placed over the heater terminals and 10 used
61. ve shaft to wear out prematurely Worn bearings may also cause excessive slurry cup run out The filter regulator lubricator unit FRL supplies lubrication and filtration for the pump air This unit is attached to the pump air inlet after the solenoid valve The filter unit is upstream of the regulator unit and it should be checked periodically and the bowl cleaned if filled with water or debris The lubricator is located just downstream of the filter A quality grade of lubricating oil approximately SAE 10 should be added routinely to the plastic reservoir otherwise it will run dry and leave the air side of the 30 Do not pour the lubricating oil into the filter bowl by mistake pump un lubricated perhaps leading to premature failure of the pump Potentiometer Mechanism Pot Mech Maintenance Refer to drawing 2 0050 in Chapter 6 for an exploded view of a potentiometer mechanism assembly 1 Check upper and lower bearings for smooth friction free operation If bearing operation is not smooth clean or replace the bearings If the bearings do not operate smoothly it may cause thickening times to increase Check for broken wires in the potentiometer resistor The resistance should measure between 80 and 100 Q The surface of the resistor that is in contact with the wiper may be burnished with a smooth round rod such as a screwdriver blade to reduce noise in the consistency signal if necessary Periodically chec
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